SR-02 Thermal Measurement Guidelines

Transcription

SR-02 7 Rebel LED 40mm Round Assembly
Overview
The SR-02 high brightness LED lighting assembly includes seven Rebel LEDs
soldered to our 40mm round CoolBase. The LEDs can be connected in series
or singly for full control of each LED making this assembly ideally suited for:
• Flashlights
• Bicycle Lights
• Dive Lights
• Lightsabers
• Spot lighting
• Task Lamps
• Color tuned lighting
• Fiber optic illuminators
• Accent lighting
The FR4 CoolBase features a highly efficient thermal design that matches or
outperforms* standard aluminium MCPCB bases. This can directly translate
into:
Features:
• LEDs can be configured
for series or single
operation
• Longer LED life
• Better color stability
• Reduced cooling requirements
The CoolBase makes it easy to mount the LED assembly a suitable heat
sink and to work with the assembly using standard bench top soldering and
hand tools.
A single Vishay NTC 10K Thermistor (NTHS0805N02N1002J) is mounted to
the board for continuous monitoring and foldback temperature control.
SR-02 assemblies can be ordered directly from our website at
www.luxeonstar.com/sr-02-7up.
• Super efficient base
design that matches or
outperforms aluminium
MCPCB bases
• Integrated thermistor for
continuous temperature
monitoring
• Available with all
currently produced
Rebel LEDs
• Custom assemblies can
be ordered with any color
combination of LEDs
Assembly Specifications
• RoHS compliant
Parameter
• Pb free reflow soldered
Value
Base Type
Base Thermal Performance (Not including LEDs)
Finishing
Solder Mask Color
Solder Paste
Max Operating Temperature (FR4 Base)1
Overall Dimensions (mm)
Weight
1.6mm FR4 PCB
1.5°C/W
Immersion Gold
White
AIM NC-258 No-Clean, Lead-Free
95°C
40D x 3.6H
6.7g
• Extremely low thermal
resistance
1 For maximum life, the FR4 board temperature must be kept below this value.
* Results will vary depending on the quality of the dielectric material used in the MCPCB base.
Quadica Developments Inc.
47 6th Concession Rd.
Brantford, Ontario N3T 5L7
Canada
Em: [email protected]
Ph: 1-347-223-5077
For technical questions, please contact us by email at [email protected]
The latest version of this document can always be downloaded from our website at
www.luxeonstar.com/sr-02.pdf
Document ID: SR-02
Revision: Feb 10, 2015
Page 1
Power Drivers
FlexBlock Wide Range DC Driver - Ideally suited for powering all 7 LEDs connected in series from
voltages a low as 10VDC.
BuckPuck/PowerPuck Drivers - Offers a variety of options for powering the SR-02 LEDs in parallel,
series or parallel/series configurations.
Secondary Optics
The SR-02 assembly is compatible with Khatod and Polymer 7 LED optics available from the Luxeon Star
LEDs website at:
www.luxeonstar.com/7-LED-Optics
Mounting & Cooling
Use of this assembly requires careful attention to mounting and cooling to ensure
that the junction temperature of the LEDs is kept well below the maximum rating as
specified in the LED documentation published by Philips Lumileds.
For optimal cooling, we recommend that the assembly be mounted to a suitable
heat sink (aluminum or copper) that is exposed to open air using a thermal interface
material such as our Bond-Ply© 100 pressure sensitive thermal tape or Arctic
Silver™ thermal adhesive. The bottom of the LED assembly is electrically neutral, so
it is not necessary to electrically isolate the LED base from the cooling surface.
Bottom View
The SR-02 has three mounting points for #4 screws. If you are using adhesive tape as a
thermal interface, then we recommend that the assembly also be fastened to the heat sink using
three mechanical fasteners. Before fastening the assembly to the heat sink, ensure that the two
mating surfaces are perfectly flat and clean in order to maximize heat transfer to the sink. Be careful
not to warp or distort the base by over tightening the fasteners.
You need to confirm that the assembly is being adequately cooled by testing the temperature of
each LED as described in the Measuring LED Junction Temperature section of this document.
Failure to ensure that LED junction temperatures are kept below their
maximum temperature rating will result in poor color rendering, early
degradation of light output, and premature LED failure!
Canada
Ph: 1-347-223-5077
Document ID: SR-02
Page 2
Custom Colors
For a small customization fee, the SR-02 assembly can be supplied with any color combination of Rebel
LEDs mounted to the base. Visit our website at www.luxeonstar.com/sr-02-custom for more information
and to order.
Predefined Assemblies
Once a custom LED assembly has been ordered, the assembly will be assigned a permanent
part number and will be available for re-order from our website as a predefined assembly with no
customization fees, no minimum order requirements and with quantity discounts. Visit our website at
www.luxeonstar.com/sr-02-predefined for a full list of currently available Predefined Assemblies.
Pad Connections
PAD No’s
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
+10
Connection
LED1 - Cathode (-)
LED1 - Anode (+)
LED2 - Cathode
LED2 - Anode
LED3 - Cathode
LED3 - Anode
LED4 - Anode
LED4 - Cathode
LED5 - Cathode
LED5 - Anode
LED6 - Cathode
LED6 - Anode
LED7 - Cathode
LED7 - Anode
TSens
TSens
9
10
11
J5
11
10
11
T
16
15
12
+
LED6
T
12
13
12
J6
+
2
CB
1
Canada
Ph: 1-347-223-5077
8
7
T
LED4
CoolBase7 J3 7
SR-02.com
LED3
Pb
3
LED2
J1
2+
+
8
J4
8
LED1
2
3
9
T1
T
13
T
14
LED5
TSens
LED7
13
9
3
4
T
5
4
J2
5
6
6
T
+
6
5
4+
Document ID: SR-02
Page 3
Series Operation
To power all of the LEDs simultaneously (series operation), apply solder dots to the round series
configuration pads (J1-J6). Connect a suitable current regulating driver to pad 14 (+) and pad 1 (-) as
shown in Image 1.
Image 1
Single Operation
To power and control each LED separately, simply connect a suitable current regulating driver to each pad
as shown in Image 2.
Image 2
Canada
Ph: 1-347-223-5077
Document ID: SR-02
Page 4
Measuring LED Junction Temperature
The junction temperature of each LED on the assembly must be tested to be sure it is being adequately
cooled.
To make testing easy, each LED mounted on the SR-02 assembly includes a temperature test point that
can be used to determine the LED junction temperature using the following procedure.
Required Tools
• Digital Multimeter
• Temperature measurement meter
• Thermocouple or thermistor with kapton tape and/or thermal adhesive epoxy
- or • Hand held temperature measurement probe with a tip that is smaller than the
temperature test pad on the LED assembly.
Test Procedure
1. Enter the LED Typical Thermal Resistance Junction to Thermal Pad (°C/W) RθJ-C
value from the Rebel LED datasheet into box B in the formula on page 7 of this
document.
2. Ideally the temperature should be tested with the LED assembly mounted in the
location where it will be operated.
If the assembly will be in a difficult to reach location, then you will need to attach
a thermocouple or thermistor to the assembly using kapton tape or Arctic Silver™
Thermal Adhesive epoxy so that the tip of the sensor is in direct contact with the
temperature measurement point as shown in image 3. Be sure to allow the adhesive
to fully cure and cool before testing. If the assembly is easily accessible, then you
can use a hand held temperature probe to measure the test point temperature.
Ensure that the tip of
the temperature sensor
is in direct contact with
the test point pad.
Image 3
Apply a small amount of epoxy to
encapsulate the entire
tip of the
sensor.
Image 4
Canada
Ph: 1-347-223-5077
Document ID: SR-02
Page 5
3. If you are measuring the temperature with a hand held probe, hold the probe onto the
temperature test point for at least 1 minute after the LED assembly has reached its stable
operating temperature. (Image 5) Applying a small amount of OMEGATHERM© 201 High
Thermal Conductivity Paste, or heat sink thermal grease to the pad and probe tip will help
to ensure you get an accurate reading. (Image 6)
Ensure that the tip of the
temperature probe is in firm
contact with the test point pad.
Image 5
Thermal paste around the pad and
probe will help stabilize your temperature
reading.
Image 6
4. Power up the LED assembly and allow the temperature to stabilize for at least 5
minutes.
5. After the temperature measurement has stabilized, note the test point temperature
and enter it in box A on page 7.
6. Measure the voltage across the LED you are testing (image 7) and note it in box C.
Image 7
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Document ID: SR-02
Page 6
7. Enter the current you are powering the LED at in box D.
8. Evaluate the completed formula to determine the junction temperature of the LED.
A
+ (1.5 +
Test Point
Temperature °C
ΨJ-S
°C/W
B
RθJ-C
)x(
C
x
LED Forward
Voltage Vf
D
*
)=
LED Forward
Current If
LED Junction
Temperature °C
* For maximum LED life, color stability and reliability, the calculated junction
temperature must always be at or below the temperature shown in the Max Rec1
Junction Temp °C column of the specification table on page 8 of this document.
More information about this junction measurement technique can be found in the
LUXEON LED Thermal Measurement Application Brief (AB33) published by Philips
Lumileds.
9. If you are powering all of the LEDs in series and the assembly is mounted to the center
of a symmetrically shaped heat sink in open air, then it is typically only necessary to test
a single LED to determine the junction temperature of all the LEDs.
If you are powering the LEDs singly, or if the assembly is mounted to an unusually
shaped heat sink, or will be used in an unusual operating environment, then you
will need to test each LED to ensure that the junction temperature is below it’s safe
operating point.
Thermistor Temperature Measurement
Every SR-02 assembly includes a single Vishay NTC 10K Thermistor (NTHS0805N02N1002J) mounted
near the center of the board. This thermistor is intended for continuous monitoring of the assembly during
operation and can be used as part of a foldback temperature control circuit to ensure that the assembly
does not overheat.
The thermistor does not replace the need to ensure that each LED is being adequately cooled by using the
previously described test procedure. It is only intended to be used for in situ monitoring of the entire LED
assembly.
For details on how to measure the board temperature using the thermistor, please refer to our Onboard
Thermistor Temperature Measurement Application Note.
Canada
Ph: 1-347-223-5077
Document ID: SR-02
Page 7
3.58 [0.14]
1.60 [0.06]
Assembly Drawing
J1-J6 Solder dot pads
for series operation
60
°
0°
12
+
J5
T
+
LED5
T
TSens
+
LED6
T
CB
CoolBase
]
6]
4] P
1.3
2] PCD
Ø25.8
]
08
0.
0 [Ø
Junction Temperature Test Point
0.0
0 [Ø1.0
CD
57
1.
[Ø
+
[Ø
[R
4.0
J2
04
.50
00
T
CD
.59] P
1 [Ø0
Ø3
+
LED2
+
2.
R1
0.
J1
T
Ø
Ø14.9
Ø4
LED3
Pb
T
J3
SR-02.com
LED1
LED7
+
LED4
T1
T
J6
Ø6.00 [Ø0.24]
See Note 5
J4
Canada
Ph: 1-347-223-5077
Document ID: SR-02
Page 8
Safety:
The LEDs mounted onto this assembly produce highly intense points of light. Do not stare directly at the
LEDs for any length of time.
Restricted Use:
Products produced or sold by Quadica Developments Inc. are not certified for use as critical components
in life support devices, systems, nor in medical operating room or life rescue equipment. A critical
component is any component of a life support device, system or medical/rescue equipment whose failure
to perform can be reasonably expected to cause failure or malfunction of the life support device, system or
medical operating room/life rescue equipment.
Disclaimer:
Although QUADICA DEVELOPMENTS INC. has attempted to provide the most accurate information and
services data (hereinafter “Data”), the Data is provided “as is” and may contain errors. The entire risk of
use of the data shall be with the user. QUADICA DEVELOPMENTS INC. makes no warranty, express or
implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular
purpose, regarding the contents or correctness of the Data provided or the ability of the Data to meet the
user’s needs or expectations. QUADICA DEVELOPMENTS INC. reserves the right to make changes and
corrections without notice.
You as the user agree to this disclaimer and the user agreement with the download or use of the provided
Data. In no event shall QUADICA DEVELOPMENTS INC. be liable for any direct, indirect, special,
incidental, exemplary, or consequential damages arising out of or related to the use of the Data, however
caused, regardless of theory of liability, and whether or not QUADICA DEVELOPMENTS INC. has been
advised of the possibility of such damage. This limitation shall apply notwithstanding any failure of essential
purpose or any exclusive remedy.
Canada
Ph: 1-347-223-5077
Document ID: SR-02
Page 9

SR-02 Thermal Measurement Guidelines

Transcription

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